Clutch Puller

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Clutch Puller

®

ARCTICCAT Effective Date: May, 2004

Special

Tools

Catalog

Snowmobile


FOREWORD

This publication is designed to help authorized Arctic Cat Snowmobile dealers in identifying the special tools available

from Arctic Cat Inc. Each of these special tools is identified by part number and by name. A brief function

description is also included for each special tool.

In several cases, two or more tools of those listed will serve the same purpose. Determine which of the tools will

best suit your needs and order accordingly. If additional information is required about any of the special tools, call

the Service Parts Department at Arctic Cat Inc.

Order all special tools using any of the following methods:

� NOTE: Alaskan dealers should order the special tools from their distributor at 907-272-5351.

A. For Phone Orders, call our WATS line (7 a.m. to 6 p.m. Central Time) - U.S.

1-800-279-2281

B. For Telefax Orders, call (24 hours a day, 7 days a week - after hours voice mail) 218-681-2822

C. For Mail Orders, address to ARCTIC CAT INC.

P.O. Box 810

Thief River Falls, MN 56701

ATTN: Service Parts Department

Pickup Orders require 24-hour notice. Pickup Orders will automatically be shipped 3 days after processing unless

a special pickup date is requested.

Remember to include Dealer Name

Dealer Number

Purchase Order Number

Method of Shipment (1 day or 2 day service is available)

Specify if Emergency Service Processing (ESP) is desired

1


2

TABLE OF

CONTENTS

Accessory Adapter . . . . . . . . . . . . . . . . . . . . . . . . .11

Alcohol Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Angle Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ball Hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ball Joint Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Bearing Cap Seal Protector. . . . . . . . . . . . . . . . . . .19

Bearing Removal Tool . . . . . . . . . . . . . . . . . . . . . . .24

Bearing Removal and Installation Tool . . . . . . . . . .23

Blind-Hole Bearing Puller . . . . . . . . . . . . . . . . . . . . .5

Brake Disc Socket Wrench (ACT Drive) . . . . . . . . .25

Bushing Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Carbide & Stud Specifications Gauge . . . . . . . . . . .20

Carburetor Adjustment Screwdriver (90°) . . . . . . . . .9

Carburetor Synchronizer . . . . . . . . . . . . . . . . . . . . . .8

Carburetor Synchronizing Tool Adapter. . . . . . . . . . .8

Carburetor Tool Set (Mikuni) . . . . . . . . . . . . . . . . . . .8

Chip Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Clutch Alignment Bar. . . . . . . . . . . . . . . . . . . . . . . .23

Clutch Bushing Installation Tool (Arctic) . . . . . . . . .21

Clutch Compressor . . . . . . . . . . . . . . . . . . . . . . . . .22

Clutch Compressor (Arctic Round-Shaft) . . . . . . . .22

Clutch Compressor (Comet) . . . . . . . . . . . . . . . . . .22

Clutch Puller (Arctic) . . . . . . . . . . . . . . . . . . . . . . . .21

Clutch Puller (Comet) . . . . . . . . . . . . . . . . . . . . . . .22

Compression/Pressure Tester Kit . . . . . . . . . . . . . . .7

Coolant Cap (Non-Pressurized) . . . . . . . . . . . . . . . .7

Crankshaft Bearing Remover . . . . . . . . . . . . . . . . . .4

Crankshaft Protector Cap . . . . . . . . . . . . . . . . . . . . .4

Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .24

Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .25

Drive Belt Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Drive Belt Replacement Tool . . . . . . . . . . . . . . . . . .25

Drive Clutch Spanner Wrench . . . . . . . . . . . . . . . . .22

Driven Pulley Puller . . . . . . . . . . . . . . . . . . . . . . . . .24

Driven Pulley Compressor Tool . . . . . . . . . . . . . . . .25

Driven Pulley Spring Adjustment Tool . . . . . . . . . . .25

Duck-Foot T-Handle Wrench (8 mm) . . . . . . . . . . .10

EFI Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

EFI Analyzer Test Harness . . . . . . . . . . . . . . . . . . .11

EFI Throttle Cable Jam Nut/

Oil-Injection Pump Jam Nut Wrench. . . . . . . . . .10

Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine Timing Gauge . . . . . . . . . . . . . . . . . . . . . . . .6

Exhaust Spring Pliers . . . . . . . . . . . . . . . . . . . . . . . .9

Fan Spanner Wrench (Suzuki) . . . . . . . . . . . . . . . . .5

Floating Piston Location Gauge . . . . . . . . . . . . . . .18

Floating Piston Removal Tool . . . . . . . . . . . . . . . . .18

Floating Piston Removal Tool Kit . . . . . . . . . . . . . . .19

Flywheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Flywheel Puller Insert . . . . . . . . . . . . . . . . . . . . . . . .4

Flywheel Puller/Spanner Wrench . . . . . . . . . . . . . . .3

Flywheel Spanner Wrench . . . . . . . . . . . . . . . . . . . .4

Fuel Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . .7

Fuel Pump Socket Wrench . . . . . . . . . . . . . . . . . . .10

Gas Gauge Removal Tool . . . . . . . . . . . . . . . . . . . . .9

Gas Shock Retaining Blocks . . . . . . . . . . . . . . . . . .17

Gas Shock Rod/Body Clamping Tool. . . . . . . . . . . .17

Hex Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . .14

Hex Clutch Puller (Arctic). . . . . . . . . . . . . . . . . . . . .21

Idle Speed Screw Jam Nut Wrench . . . . . . . . . . . . . 10

Idler Wheel Alignment Tool . . . . . . . . . . . . . . . . . . . 20

Idler Wheel Puller Kit . . . . . . . . . . . . . . . . . . . . . . . . 20

Ignition Test Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inflation Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inflation Needle Replacement . . . . . . . . . . . . . . . . . 18

Insert Holder (5/16 in.) . . . . . . . . . . . . . . . . . . . . . . . 15

Jack Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Linkage Wrench (8 mm). . . . . . . . . . . . . . . . . . . . . . 10

Multimeter (Fluke Model 73 w/Case) . . . . . . . . . . . . 12

Nitrogen Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 17

Oil Filter Wrench (Adjustable) . . . . . . . . . . . . . . . . . . 9

Oil Injection Usage Tool . . . . . . . . . . . . . . . . . . . . . . . 8

Oil Seal Installation Tool. . . . . . . . . . . . . . . . . . . . . . . 5

Peak Voltage Reading Adapter . . . . . . . . . . . . . . . . 12

Phillips-Head Bits (1/4 in. Hex Drive) . . . . . . . . . . . . 14

Pinion Shimming Tool

(650 and 700 cc Engines) . . . . . . . . . . . . . . . . . . . . 5

Piston Location Tool . . . . . . . . . . . . . . . . . . . . . . . . . 18

Piston Pin Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Quick-Disconnect Coupler . . . . . . . . . . . . . . . . . . . . 15

Rear Axle Nut Socket. . . . . . . . . . . . . . . . . . . . . . . . 15

Rear Shock Adjuster . . . . . . . . . . . . . . . . . . . . . . . . 15

Rear Suspension Spring Tool. . . . . . . . . . . . . . . . . . 15

Replacement Bolt (Center). . . . . . . . . . . . . . . . . . . . 17

Replacement Bolt (Side) . . . . . . . . . . . . . . . . . . . . . 17

Replacement Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . 14

Reverse Gear Adjustment Gauge . . . . . . . . . . . . . . 24

Rigid Hone Stone Set (2.7-4.1 in.) . . . . . . . . . . . . . . . 6

Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rivnut Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Rivnut Tool Insert Bit . . . . . . . . . . . . . . . . . . . . . . . . 13

Roller Pin Removal Tool. . . . . . . . . . . . . . . . . . . . . . 24

Shock Absorber Air Pump . . . . . . . . . . . . . . . . . . . . 16

Shock Rod Clamping Tool . . . . . . . . . . . . . . . . . . . . 17

Shock Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . 16

Shock Spring Removal Tool . . . . . . . . . . . . . . . . . . . 15

Side Guard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Spider Removal Kit . . . . . . . . . . . . . . . . . . . . . . . . . 21

Spring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Starter Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . 7

Stud Runner (6, 8, & 10 mm) . . . . . . . . . . . . . . . . . . 13

Surface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Synchronizer Repair Kit . . . . . . . . . . . . . . . . . . . . . . . 8

T-Handle Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

T Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Throttle Position Sensor (TPS)

Adjustment Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 12

Timing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Torx Bit Insert (5/16 in. Hex Drive) . . . . . . . . . . . . . . 14

Torx Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . . 14

Track Clip Installation Tool . . . . . . . . . . . . . . . . . . . . 19

Track Stud Hole Drill (7 mm) . . . . . . . . . . . . . . . . . . 20

Track Stud Hole Drill (1/4 in.) . . . . . . . . . . . . . . . . . . 20

V Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Vacuum Test Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water Pump Bearing & Seal Kit . . . . . . . . . . . . . . . . . 5

Zipper Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


Piston Pin Puller

p/n: 0644-328 (Complete Set)

p/n: 0643-073 (Extractor Nut Only-Small)

p/n: 0643-074 (Extractor Nut Only-Medium)

p/n: 0643-075 (Extractor Nut Only-Large)

p/n: 0643-072 (Threaded T-Handle)

Usage: Remove piston pins.

Fig. 1

0644-328

Ring Compressor

p/n: 0644-378

Usage: Compress piston rings for cylinder installation.

Features a quick-release function for removing tool from

underside of piston.

Fig. 2

0644-378

Flywheel Puller

p/n: 0644-423 (Complete Set)

p/n: 0643-086 (Body)

p/n: 0643-087 (Bolt)

p/n: 0423-482 (6 mm Cap Screw)

p/n: 0423-483 (8 mm Cap Screw)

Usage: Pull flywheel off crankshaft on all Arctic Cat 2stroke

models.

Fig. 3

0644-423

Flywheel Puller/Spanner Wrench

p/n: 0144-310

Usage: Pull flywheel off crankshaft and hold Arctic-style

clutches.

Fig. 4

AE047

3


Flywheel Spanner Wrench

p/n: 0144-007

Usage: Hold starter cup while removing/installing flywheel

nut.

Fig. 5

4

AE030

Flywheel Puller Insert

p/n: 0644-179

Usage: Protect the crankshaft end on the 900 cc engine

during flywheel removal.

Fig. 6

Crankshaft Protector Cap

p/n: 0644-234

Usage: Protect the crankshaft end during flywheel

removal.

Fig. 7

AE109

0644-234

Crankshaft Bearing Remover

p/n: 0144-302

Usage: Remove crankshaft bearings.

Fig. 8

Surface Plate

p/n: 0644-016

Usage: True sealing surfaces.

Fig. 9

V Blocks

p/n: 0644-022

Usage: Check crankshaft runout.

Fig. 10

AE043

AE058

0644-022


Fan Spanner Wrench (Suzuki)

p/n: 0644-340

Usage: Hold fan in place during disassembly and

assembly.

Fig. 11

AE104

Engine Stand

p/n: 0644-079

Usage: Hold engine during assembling/disassembling.

Fig. 12

Pinion Shimming Tool (650 and

700 cc Engines)

p/n: 0644-055

Usage: Determine size and number of pinion gear

shims.

Fig. 13

AE079

AE073

Water Pump Bearing & Seal Kit

p/n: 0644-084

Usage: Remove/install crankcase water pump bearings

and seals.

Fig. 14

AE080

Oil Seal Installation Tool

p/n: 0644-219

Usage: Install the oil seal on the water pump driveshaft

on the 440, 550, 580, 650, 700, 800, and 900 cc Arctic

Cat engines.

Fig. 15

Blind-Hole Bearing Puller

p/n: 0644-381

Usage: Remove small and large blind bearings on all

models.

Fig. 16

AE130

0644-381

5


Rigid Hone Stone Set (2.7-4.1 in.)

p/n: 0644-043

Usage: Replacement stones for Cylinder Hone Set (p/n

0644-041).

Fig. 17

6

AE068

Ball Hone

p/n: 0644-290 (60-64 mm)

p/n: 0644-291 (65-70 mm)

p/n: 0644-292 (72-74 mm)

p/n: 0644-293 (76-83 mm)

p/n: 0644-294 (83-88 mm)

Usage: Deglaze Nicosil plated cylinders. All are 320 grit

and are recommended for reconditioning all Arctic Cat

snowmobile engine cylinders (1976-2000).

Fig. 18

Ignition Test Plug

p/n: 0144-306

Usage: Test engine ignition.

Fig. 19

AE065

AE045

Angle Finder

p/n: 0644-097

Usage: Identify levelness and pitch.

Fig. 20

Engine Timing Gauge

p/n: 0144-009

Usage: Static time engines without CDI ignition.

Fig. 21

Timing Light

p/n: 0644-296

Usage: Check ignition timing.

Fig. 22

AE090

AE031

AE054


Starter Assembly Tool

p/n: 0644-052

Usage: Hold brushes for assembling UTC brand starter

motor.

Fig. 23

AE072

Compression/Pressure Tester Kit

p/n: 0644-366 (Complete Kit w/Case)

p/n: 0644-388 (T-Fitting - Fuel Pressure Gauge)

p/n: 0644-133 (Three Carburetor Plugs)*

p/n: 0644-176 (Three Rubber Gaskets)*

p/n: 0644-177 (Three Exhaust Plates)*

p/n: 0644-367 (Twelve 8 mm Nuts and Bolts)

p/n: 0644-368 (Vacuum Plugs)

p/n: 0644-369 (Two Exhaust Plates)*

p/n: 0644-370 (Three Exhaust Valve Cover

Plates - Standard APV Engine)*

p/n: 0644-406 (Exhaust Valve Cover

Plates - Laydown APV Engine)*

p/n: 0644-371 (8 mm Oil Pressure Adapter)

p/n: 0644-372 (10 mm Compression Tester

Adapter)

p/n: 0644-373 (12 mm Compression Tester

Adapter)

p/n: 0644-374 (Hose Assembly)

p/n: 0644-375 (Oil/Fuel Pressure Gauge)

p/n: 0644-376 (Compression Gauge)

p/n: 0644-377 (Leak-Down Tester Gauge)

Usage: Test all compression/pressure-related assemblies

on all Arctic Cat products. Contains all necessarycomponents

to test oil/fuel pressure, compression, and

leak-down. *Can be ordered individually.

Fig. 24

644-366A

Fuel Pressure Tester

p/n: 0644-203

Usage: Test fuel pressure on both EFI and carbureted

models. A valuable tool for troubleshooting EFI fuel systems.

Fig. 25

AE124

Coolant Cap (Non-Pressurized)

p/n: 0644-156

Usage: Fill cooling system on the 1992, 1995, and 1996

models equipped with bleed system.

Fig. 26

Vacuum Test Pump

p/n: 0644-131

Usage: Check components for air leaks.

Fig. 27

AE129

AE099

7


Oil Injection Usage Tool

p/n: 0644-007

Usage: Measure exact amount of oil used by the oil

injection pump during a given time period.

Fig. 28

Alcohol Test Kit

p/n: 0644-044

Usage: Test gasoline for alcohol.

Fig. 29

Carburetor Synchronizer

p/n: 0644-069

Usage: Synchronize Mikuni carburetors.

Fig. 30

8

AE108

AE069

AE076

Carburetor Synchronizing Tool

Adapter

p/n: 0644-023

Usage: Threads into carburetor fitting and slides into

synchronizer hose.

Fig. 31

Carburetor Tool Set (Mikuni)

p/n: 0636-072

Usage: Disassemble/assemble Mikuni carburetors.

Fig. 32

CE029

AE049

Synchronizer Repair Kit

p/n: 0644-062

Usage: Replacement components for Carburetor Synchronizer

(p/n 0644-069).

Fig. 33

AE138


Carburetor Adjustment

Screwdriver (90°)

p/n: 0644-289

Usage: Make carburetor adjustments on all twin and triple

cylinder engines. Will be especially useful for adjusting

the pilot circuit screw on all TM-style carburetors.

Fig. 34

Gas Gauge Removal Tool

p/n: 0644-357

Usage: Remove gauge from the gas tank.

Fig. 35

Exhaust Spring Pliers (0°)

p/n: 0644-391

Usage: Remove/install exhaust springs.

Fig. 36

0644-289

0644-357

644-391A

Exhaust Spring Pliers (90°)

p/n: 0644-397

Usage: Remove/install exhaust springs.

Fig. 37

Spring Tool

p/n: 0644-072

Usage: Remove/install exhaust springs.

Fig. 38

0644-397

Oil Filter Wrench (Adjustable)

p/n: 0644-389

Usage: Remove oil filters from 4-stroke engines. Features

adjustments between 62-96 mm.

Fig. 39

AE077

0644-389

9


EFI Throttle Cable Jam Nut/Oil-

Injection Pump Jam Nut Wrench

(10 mm)

p/n: 0644-242

Usage: Loosen and tighten jam nuts on both the oilinjection

pump and EFI throttle cable.

Fig. 40

Duck-Foot T-Handle Wrench

(8 mm)

p/n: 0644-332

Usage: Adjust oil-injection pump mechanical linkage.

Fig. 41

Linkage Wrench (8 mm)

p/n: 0644-333

Usage: Adjust oil-injection pump mechanical linkage.

Fig. 42

10

BE024

BE024

0644-333

Idle Speed Screw Jam Nut

Wrench

p/n: 0644-311

Usage: Loosen/tighten idle speed screw jam nut on batteryless

EFI system.

Fig. 43

0644-311

Fuel Pump Socket Wrench

p/n: 0644-364

Usage: Remove plastic nut securing the fuel pump to

the gas tank.

Fig. 44

0644-364

Chip Puller

p/n: 0644-188

Usage: Safely remove EPROM chip from the ECU on all

EFI models.

Fig. 45

AE117


EFI Analyzer

p/n: 0644-342

p/n: 0644-422 (Harness)

p/n: 0644-341 (Complete Kit)

p/n: 0643-081 (EPROM)

p/n: 0686-716 (Harness)

Usage: Troubleshoot all Arctic Cat EFI systems. A valuable

tool to assist the technician in locating EFI problems

quickly.

Fig. 46

0644-342

EFI Analyzer Test Harness

p/n: 0644-181

Usage: Troubleshoot EFI system (1993-1996 models).

Fig. 47

AE113

EFI Analyzer Test Harness

p/n: 0644-624

Usage: Troubleshoot EFI battery system (1997-1998

models).

Fig. 48

AE143

Tachometer

p/n: 0644-386

Usage: Measure engine RPM for 2-stroke and 4-stroke

engines.

Fig. 49

0644-386

Accessory Adapter

p/n: 0644-387

Usage: With Tachometer (p/n 0644-386), measure RPM

for diesel engines.

Fig. 50

0644-387

11


Throttle Position Sensor (TPS)

Adjustment Tool Kit

p/n: 3639-891 (Complete Set)

p/n: 0686-999 (Harness Only)

p/n: 0644-359 (Torx-Head Screwdriver - #25

Only)

p/n: 0644-344 (Torx-Head Screwdriver - #30

Only)

p/n: 0644-345 (Pin Gauge Only)

Usage: Precisely adjust the throttle position sensor on

carbureted and EFI models.

Fig. 51

Battery Charger

p/n: 0436-634

Usage: Charge sealed, maintenance-free batteries.

Fig. 52

12

3639-891

0436-634

Zipper Case

p/n: 0644-190

Usage: Protect the Fluke Multimeter.

Fig. 53

0644-190

Peak Voltage Reading Adapter

p/n: 0644-307

Usage: With Fluke Model 73 Multimeter (p/n 0644-191),

read peak voltage.

Fig. 54

Multimeter (Fluke Model 73 w/

Case)

p/n: 0644-191

Usage: Ditgital multimeter accurate to within ± 0.5%.

Fig. 55

0644-307

AE114


Stud Runner

p/n: 0644-018 (6 mm)

p/n: 0644-019 (8 mm)

p/n: 0644-020 (10 mm)

Usage: Install studs on cylinders and crankcase.

Fig. 56

T Wrench

p/n: 0644-021

Usage: Drive 3/8 in. square-drive sockets.

Fig. 57

T-Handle Wrench

p/n: 0644-257 (8 mm)

p/n: 0644-024 (10 mm)

p/n: 0644-025 (12 mm)

p/n: 0644-026 (14 mm)

Usage: Remove and install nuts and bolts.

Fig. 58

AE059

AE060

AE115

Rivnut Tool

p/n: 0644-232

Usage: Collapse and install rivnuts.

Fig. 59

0644-232

Rivnut Tool Insert Bit

p/n: 0644-233 (1/4 x 20)

p/n: 0644-405 (10-32)

p/n: 0644-430 (5/16 x 18)

p/n: 0644-431 (3/8 x 16)

Usage: With Rivnut Tool (p/n 0644-232) and Replacement

Rivnuts, replace rivnuts.

Fig. 60

0644-233

13


Replacement Rivnuts

p/n: 0623-557 (1/4 x 20)

p/n: 0623-582/627 (1/4 x 20)

p/n: 0623-581 (5/16 x 18)

p/n: 0623-699 (3/8 x 16)

p/n: 0623-874 (8-32)

p/n: 0623-529/779 (10-32)

Usage: With Rivnut Tool (p/n 0644-232), replace rivnuts.

Fig. 61

14

0623-557

Hex Bits (1/4 in. Hex Drive)

p/n: 0644-317 (5 mm)

p/n: 0644-316 (6 mm)

Usage: With Quick-Disconnect Coupler (p/n 0644-308),

remove and install bolts and screws.

Fig. 62

0644-316

Phillips-Head Bits (1/4 in. Hex

Drive)

p/n: 0644-319 (#2)

p/n: 0644-318 (#3)

Usage: With Quick-Disconnect Coupler (p/n 0644-308),

remove and install Phillips-head screws.

Fig. 63

0644-318

Torx Bits (1/4 in. Hex Drive)

p/n: 0644-312 (#25)

p/n: 0644-393 (#27)

p/n: 0644-215 (#30)

p/n: 0644-313 (#40)

Usage: With Quick-Disconnect Coupler (p/n 0644-308),

remove and install torx-head screws.

Fig. 64

BE012

Torx Bit Insert (5/16 in. Hex Drive)

p/n: 0644-314

Usage: With Insert Holder (p/n 0644-315), remove and

install torx-head screws.

Fig. 65

BE012


Insert Holder (5/16 in.)

p/n: 0644-315

Usage: With Torx Bit Insert (p/n 0644-314), remove and

install torx-head screws.

Fig. 66

0644-315

Quick-Disconnect Coupler

p/n: 0644-308

Usage: Hold 1/4 in. hex drive Torx Bits (Fig. 64), Hex

Bits (Fig. 62), and Phillips-Head Bits (Fig. 63).

Fig. 67

Rear Suspension Spring Tool

p/n: 0144-311

Usage: Install/remove rear suspension springs.

Fig. 68

0644-308

AE048

Rear Axle Nut Socket

p/n: 0644-399

Usage: Loosen/tighten rear axle nut on 2004 and earlier

AWS VI models.

Fig. 69

Rear Shock Adjuster

p/n: 0644-015

Usage: Rotate rear shock adjusting cam on external

AFS models.

Fig. 70

Shock Spring Removal Tool

p/n: 0644-057

Usage: Remove/install shock absorber spring.

Fig. 71

0644-399

AE057

AE074

15


Shock Spanner Wrench

p/n: 2604-878

Usage: Adjust pre-load on Fox Zero Pro shock absorber.

Fig. 72

16

2604-878

Shock Spanner Wrench

p/n: 0644-398

Usage: Adjust pre-load on front arm rebuildable shock

absorber.

Fig. 73

Shock Spanner Wrench

p/n: 0644-305

Usage: Adjust pre-load on front arm standard shock

absorber.

Fig. 74

0644-398

0644-305

Shock Absorber Air Pump

p/n: 2603-324

Usage: Adjust air pressure on Fox Air Shocks.

Fig. 75

Jack Stand

p/n: 0644-076 (Standard Models - Low)

p/n: 0639-462 (ETT Models - High)

Usage: Support rear of snowmobile off the ground.

Fig. 76

Side Guard Kit

p/n: 0639-611

Usage: With Jack Stand (p/n 0644-076/0639-462).

Fig. 77

2603-324

AE133

0639-611


Replacement Bolt (Side)

p/n: 0644-101

Usage: Replaces side bolt in Track Clip Tool (p/n 0144-

301).

Fig. 78

Replacement Bolt (Center)

p/n: 0644-103

Usage: Replaces center bolt in Track Clip Tool (p/n

0144-301).

Fig. 79

Shock Rod Clamping Tool

p/n: 0744-021

Usage: Hold shock absorber rod for servicing.

Fig. 80

AE093

AE094

AE145D

Gas Shock Rod/Body Clamping

Tool

p/n: 0644-425

Usage: Hold gas shock absorber for servicing.

Fig. 81

0644-425

Gas Shock Retaining Blocks

p/n: 0644-334

Usage: Hold gas shock secure during disassembly and

assembly.

Fig. 82

Nitrogen Regulator

p/n: 0644-151

Usage: Recharge rebuildable gas shock absorbers.

Fig. 83

AP042

AE095

17


Inflation Needle

p/n: 0744-020

Usage: Pressurize rebuildable gas shock absorbers with

nitrogen.

Fig. 84

18

AE110

Inflation Needle Replacement

p/n: 0644-162

Usage: Replacement needle assembly for Inflation Needle

(p/n 0744-020).

Fig. 85

0644-162

Piston Location Tool

p/n: 0644-169

Usage: Precisely locate the floating piston in the rebuildable

gas shock absorber.

Fig. 86

AE135

Floating Piston Location Gauge

p/n: 0644-350

Usage: Precisely locate and measure floating piston

depth without use of a calipers.

Fig. 87

0644-350

Floating Piston Removal Tool

p/n: 0644-348

Usage: Remove floating piston from cross-link suspension

shocks on 2002 models.

Fig. 88

0644-348


Floating Piston Removal Tool Kit

p/n: 0644-402 (Complete Kit)

p/n: 0644-416 (Removal Tool)

p/n: 0644-417 (Location Gauge)

p/n: 0644-418 (Gauge Set Screw)

p/n: 0644-419 (Gauge Stop Collar)

Usage: Remove floating piston from rebuildable gas

shock absorbers.

Fig. 89

0644-402

Bearing Cap Seal Protector

p/n: 0644-268

Usage: Protect cap seal on rebuildable shock absorbers

through 2002 models.

Fig. 90

AE142

Bearing Cap Seal Protector

p/n: 0644-403 (1/2 in.)

p/n: 0644-404 (5/8 in.)

Usage: Protect cap seal on rebuildable shock absorbers

on 2003 and newer models.

Fig. 91

Ball Joint Fork

p/n: 0644-098

Usage: Separate ball joint from spindle or drag link.

Fig. 92

AE142

AE091

Track Clip Installation Tool

p/n: 0644-194

Usage: Install track clips on Camoplast and Yokohama

rubber tracks.

Fig. 93

0644-194

19


Track Stud Hole Drill (7 mm)

p/n: 1639-629

Usage: Drill 7 mm hole through rubber tracks for installing

studs.

Fig. 94

20

AE137

Track Stud Hole Drill (1/4 in.)

p/n: 1639-628

Usage: Drill 1/4 in. hole through rubber track for installing

studs.

Fig. 95

Carbide & Stud Specifications

Gauge

p/n: 1639-632

Usage: Check stud length and carbide angle.

Fig. 96

AE137

AE088

Idler Wheel Puller Kit

p/n: 0644-122 (Complete Kit - 6 in.)

p/n: 0644-400 (Complete Kit - 8 in.)

p/n: 0644-114 (A. Handle - 6 in.)

p/n: 0644-401 (A. Handle - 8 in.)

p/n: 0644-111 (B. Insertion Tool)

p/n: 0644-120 (C. Pivot Plate)

p/n: 0644-118 (D. Adapter Plate)

p/n: 0623-310 (E. Cap Screw)

p/n: 0644-119 (F. Puller Bolt) - 6 in. Kit

p/n: 0644-432 (F. Puller Bolt) - 8 in. Kit

Usage: Remove/install skid frame idler wheels.

Fig. 97

Idler Wheel Alignment Tool

p/n: 0644-228

Usage: Align center idler wheels during replacement

without removing the suspension.

Fig. 98

AE097B

BE025


Spider Removal Kit

p/n: 0644-449 (Complete Kit)

p/n: 0744-037 (Handle)

p/n: 0744-036 (Removal Tool)

p/n: 0644-380 (Clutch Holder - 33 mm)

p/n: 0744-035 (Clutch Holder - 30 mm)

p/n: 0644-138 (Thin Wall Deep Socket - 1 7/16 in.)

Usage: Disassemble/assemble/remove spider on Comet

and Arctic drive clutches.

p/n: 0644-380 (33 mm)

Usage: Hold clutch stationary sheave for 33 mm crankshaft

on 2001 and later 800/900 cc and 2003 and later

700 cc “Laydown” engines.

p/n: 0744-035 (30 mm)

Usage: Aid in assembling/disassembling of 108 & 102C

Comet and Arctic drive clutches.

p/n: 0644-138 (1 7/16 in.)

Usage: Remove and install spider nut on Arctic roundshaft

drive clutch.

Fig. 99

0644-449

Clutch Bushing Installation Tool

(Arctic)

p/n: 0644-006

Usage: Replace sheave/cover bushings on Arctic hexdrive

clutches.

Fig. 100

AE053

Hex Clutch Puller (Arctic)

p/n: 0644-010

Usage: Remove Arctic hex-drive clutch from crankshaft.

Fig. 101

AE056

Clutch Puller (Arctic)

p/n: 0644-207

Usage: Remove Arctic round-shaft drive clutch from the

crankshaft.

Fig. 102

AE125

21


Clutch Puller (Comet)

p/n: 0644-096

Usage: Remove Comet drive clutch (short bolt w/

retainer plug style).

Fig. 103

Clutch Puller (Comet)

p/n: 0644-100

Usage: Remove Comet drive clutch (long bolt style).

Fig. 104

Clutch Compressor (Arctic

Round-Shaft)

p/n: 0644-245

Usage: Compress and hold Arctic round-shaft drive

clutch in the compressed position for changing cam

arms.

Fig. 105

22

AE089

AE055

AE132

Clutch Compressor (Comet)

p/n: 0644-123

Usage: Compress and hold drive clutch in the compressed

position for changing cam arms.

Fig. 106

AE098

Clutch Compressor

p/n: 0644-420

Usage: Compress and hold drive clutch in the compressed

position for changing cam arms and removing/

installing six-post drive clutch on AWS VI models.

Fig. 107

0644-420

Drive Clutch Spanner Wrench

p/n: 0644-136

Usage: Hold Comet and Arctic round-shaft drive clutch

in place during removal and installation.

Fig. 108

AE101


Bushing Tool Kit

p/n: 0644-137

Usage: Remove and install cover plate and movable

sheave bushings in Arctic round-shaft drive clutch

through 1998.

Fig. 109

AE127A

Bearing Removal and Installation

Tool

p/n: 0644-167

Usage: Remove and install bearings in the driven clutch

movable sheave and button plate.

Fig. 110

AE112

Clutch Alignment Bar (1.365 in.

Offset)

p/n: 0644-320

Usage: Align the drive clutch and driven pulley on models

using the reverse cam driven pulley.

Fig. 111

AE052A

Clutch Alignment Bar (1.562 in.

Offset)

p/n: 0644-246

Usage: Align drive clutch and driven pulley on 1997

models using the Arctic internal-helix driven pulley.

Fig. 112

AE140

Clutch Alignment Bar (1.485 in.

Offset)

p/n: 0644-428

Usage: Align drive clutch and driven pulley on Bearcat

Wide Track models.

Fig. 113

0644-428

Clutch Alignment Bar (1.620 in.

Offset)

p/n: 0644-427

Usage: Align drive clutch and driven pulley on ACT Drive

models.

Fig. 114

AE052A

23


Reverse Gear Adjustment Gauge

p/n: 0644-244

Usage: Adjust reverse gear linkage on all 1996-2002

reverse gear transmissions.

Fig. 115

Driven Pulley Puller

p/n: 0744-023

Usage: Remove driven pulley from driven shaft. It can

be used on both the roller and button style.

Fig. 116

24

BE027

0744-023

Roller Pin Removal Tool

p/n: 0644-276

Usage: Remove roller pins from retainer plate on driven

pulley.

Fig. 117

AE146D

Bearing Removal Tool

p/n: 0644-421

Usage: Remove chain case bearings on 2003 and

newer models.

Fig. 118

Drive Belt Gauge

p/n: 0644-443

Usage: Measure drive belt width.

Fig. 119

0644-421

0644-443

Drive Belt Deflection Tool

p/n: 0644-412

Usage: Adjust driven pulley for proper drive belt deflection

and aid in drive belt removal on models using the

ACT Roller Driven Pulley.

Fig. 120

0644-412


Drive Belt Replacement Tool

p/n: 0644-435

Usage: Replace drive belt and adjust belt deflection on

models using the ACT Roller Driven Pulley.

Fig. 121

0644-435

Driven Pulley Spring Adjustment

Tool

p/n: 0644-413

Usage: Adjust driven pulley spring pre-load on models

using the ACT Driven Pulley.

Fig. 122

0644-413

Drive Belt Deflection Tool

p/n: 0644-424

Usage: Adjust driven pulley for proper drive belt deflection

and aid in drive belt removal on 2004 440 Sno Pro

model.

Fig. 123

0644-424

Driven Pulley Compressor Tool

p/n: 0644-444

p/n: 0644-439 (A. Compressor Assembly Only)

p/n: 0643-095 (B. Disc Only)

Usage: Disassemble/assemble Arctic ACT and Team

Industries roller driven pulleys.

Fig. 124

644-444A

Brake Disc Socket Wrench

(ACT Drive)

p/n: 0644-415

Usage: Remove/install brake disc on ACT Drive models.

Fig.125

0644-415

25


Printed in U.S.A. ®Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2257-251

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